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Old Feb 12th, 2011, 16:36   #2
rtbcomp
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Last Online: Apr 9th, 2024 15:02
Join Date: May 2007
Location: Sheffield
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With the relay exposed, press the clapper of each relay in turn and each pump should run. If not and the fuses have been check out there could be a fault with the pump(s) or wiring thereto or there may be a dry joint on the relay circuit board.

If the pumps run OK then you could still have a dry joint or the ECU isn't doing its job.

Dry joints show as ring in the solder around the pin on the solder side of the circuit board, simply melt the solder with a 25 watt iron and add a bit of new flux-cored solder to re-flow the joint. You can use flux without extra solder, but on no account use aggressive plumbing fluxes, use proper electrical flux. Otherwise the joints might corrode, (don't ask how I know).

If the relay still doesn't work then you'll have to fit a new one.

This is a general view showing the relay with its cover off and the glovebox light disconnected. Bear in mind when doing all this that the big bit of exposed copper in the relay is at 12volts, so don't let it touch the bodywork!

1992 240 SE Fuel Pump Relay 03.jpg

Last edited by rtbcomp; Feb 12th, 2011 at 16:42. Reason: Add picture
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